Shingle with interlocking water diverter tabs

ABSTRACT

A shingle includes a body having a top surface, a bottom surface, an upper end, a lower end, a first side, and a second side. The body has a width defined as the distance between the first and second sides and a length defined by the distance between the upper and lower ends. In a preferred embodiment, the shingle also includes a water diverter tab attached to the first side for channeling water onto the top surface of a lower adjacent shingle, and a recess adjacent to the second side for receiving the water diverter tab of a laterally adjacent shingle in an interlocking manner. An anchor tab attached to the second side secures the lower ends of adjacent, interlocked shingles.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 60/552,418 entitled Shingle with Interlocking WaterDiverter Tabs, filed Mar. 11, 2004, the disclosure of which isincorporated herein.

FIELD OF THE INVENTION

The present invention is generally related to improved buildingmaterials and more particularly related to shingles for roofingapplications requiring resistance to high winds.

BACKGROUND OF THE INVENTION

The vast majority of roofing shingles in America are comparativelyinexpensive, and are made from thin sheets of asphalt-coated buildingmaterials that are used in overlapping rows to protect the interior of ahouse from inclement weather. By contrast, the more expensive,“specialty” shingles have historically been constructed from a number ofthicker, natural compositions, including natural slate, clay, wood andconcrete. Recently, advances in polymer technology have enabled a newclass of “synthetic” shingles to emerge, such that the look of moreexpensive natural materials can be mimicked by injection moldedsynthetic shingles, often at a lower total-installed cost.

Prior art synthetic shingles are typically rectangular in shape and havesubstantially flat top and bottom surfaces. These types of shingles arecustomarily installed by securing a first horizontal row, or “course,”of shingles along the bottom of the roof in a line parallel to theroofline, or “eave.” Shingles are secured independently, one shingle ata time, with what is typically a small gap or “keyway” between adjacentshingles. Also, in prior art shingles, each successive course ofshingles overlays the previous course of shingles by at least 50%, sothat precipitation of any kind will cascade down the roof, from onecourse of shingles to the next, so that water is conveyed from shinglesat the top ridge of the structure down across the surface of theshingles, course after course, until it is shed from the roof safely togutters or otherwise off of the home or building. The importance ofoverlapping shingles on a lower course with shingles on the next highercourse by at least 50% is to ensure that water that flows down the roofstructure does not trickle through the keyways between shingles in a waythat would create the risk of water leaking down onto any of theunderlying roof structure (underlayment materials or roof deck), whichultimately protects the valuable contents and inhabitants of any roofedstructure.

Although widely accepted, prior art shingles and installation methodssuffer a number of drawbacks. A large portion of each shingle isdedicated to providing the horizontal overlap needed to protect theunderlying roof material from water draining into the keyways. Thislimits the percentage of actual exposure area provided by each prior artshingle to roughly 50% of its total size, and thereby increases theamount of roofing material actually required to successfully shed waterfrom a roof by a factor of two. In addition, it is very difficult tomaintain consistent alignment of the horizontal rows of shingles acrossthe entire roof surface. Improper, uneven tilting of a single shingle ina way that is not exactly parallel to the eave can produce anexaggerated misalignment of subsequent adjacent shingles that arepositioned with reference to the single improperly placed, unevenshingle. Accordingly, there is a need for an improved shingle thatovercomes these and other deficiencies in the prior art.

SUMMARY OF THE INVENTION

In a preferred embodiment, the present invention includes a shingleconfigured for attachment to a roof. The shingle preferably includes abody having a first side wall and a second side wall, a water divertertab attached to the first side wall and an anchor tab attached to thesecond side wall. The present invention also includes a method forinstalling shingles constructed in accordance with the preferredembodiment. The method includes the steps of securing a first shingle toan underlying surface by inserting at least one fastener through anupper end of the first shingle and at least one fastener through ananchor tab extending from a first side of the first shingle;interlocking a second shingle with the first shingle by inserting awater diverter tab connected to the second side of the second shinglethrough a water diverter tab opening in the first side of the firstshingle; and securing the second shingle to the underlying surface byinserting at least one fastener through an upper end of the secondshingle and at least one fastener through an anchor tab extending from afirst side of the second shingle.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view of a shingle constructed in accordance with apreferred embodiment of the present invention.

FIG. 2 is a perspective view of the top of a shingle constructed inaccordance with a preferred embodiment of the present invention.

FIG. 3 is a perspective view of the bottom of the shingle of FIG. 1.

FIG. 4 is an elevational view of the lower end of the shingle of FIG. 3.

FIG. 5 is an elevational view of the lower end of two shingles duringinstallation.

FIG. 6 is an elevational view of the lower end of two shingles duringinstallation with a partial cutaway to reveal the interlocked waterdiverter tab and anchor tab.

FIG. 7 is a top plan view with a partial cutaway of two shingles duringinstallation with a partial cutaway to reveal the interlocked waterdiverter tab and anchor tab.

FIG. 8 is an elevational view of the second side of two verticallyoverlapping shingles constructed in accordance with the presentinvention.

FIG. 9 is an elevational view of the first side of the shingles of FIG.8.

FIG. 10 is cross-sectional view of the first side of one of the shinglesof FIG. 8 with the water diverter tab removed.

FIG. 11 is a top view of a preferred installation of a plurality of theshingles constructed in accordance with a preferred embodiment of thepresent invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

FIG. 1 shows a shingle 100 constructed in accordance with a preferredembodiment of the present invention. The shingle 100 has a body 101, ananchor tab 114, and a water diverter tab 116. The body 101 includes atop surface 102, a bottom surface 103 (shown in FIG. 3), a lower(“butt”) end 104, an upper (“tip”) end 106, a first side 108 and asecond side 110. The shingle 100 preferably includes one or morefastener receiver areas 112 proximate the tip end 106. The fastenerreceiver areas 112 can be used to secure the upper end 106 of theshingle 100 to the underlying roof materials and roof deck through useof common fasteners, such as nails or screws. In a particularlypreferred embodiment, the shingle 100 also includes a first side wall109 adjacent to and extending downward from the first side 108, a secondside wall 111 adjacent to and extending downward from the second side110. The shingle 100 also includes a lower end wall 113 and an upper endwall 115 that extend downward from the lower and upper ends 104, 106.

In the presently preferred embodiment, the shingle 100 is constructedfrom synthetic materials. In a particularly preferred embodiment, theshingle 100 is constructed from one or more plastics that exhibitsuitable flexibility and resilience to enable the use of standardroofing nails or standard roofing screws during the installation of theshingle 100. The materials selected for the construction of the shingle100 should also permit the creation of selected textures on the topsurface 102. For example, the shingle 100 may include a texture thatresembles slate, clay tile, wood shake, tile or concrete tile shingles.Polyethylene-based plastics are presently preferred as the material ofconstruction. Although synthetic materials are presently preferred, itwill be understood that alternative formable materials, such as, forexample, other polymers, metals, clay, concrete and ceramics, could alsobe used.

Referring now also to FIGS. 2-4, shown therein are a top perspectiveview, bottom perspective view and lower end elevational view,respectively, of the shingle 100. The shingle 100 preferably includes ananchor tab 114 connected to the second side 110 and a water diverter tab116 connected to the first side 108. The anchor tab 114 is preferablyconfigured to receive a suitable anchor, such as a nail or a screw, andis used in addition to the fastener receiver areas 112 to secure theshingle 100 to underlying roof materials. The anchor tab 114 forms abuilt-in “hurricane clip,” and generally improves the resistance of theshingle 100 to high winds. The water diverter tab 116 preferablyincludes a base 118 and a “lip” 120 that extends upward from the base118. The water diverter tab 116 forms a “gutter” that captures waterbetween the lip 120 and first side wall 109.

In a preferred embodiment, the lip 120 of the water diverter tab 116 andthe second side wall 111 are configured to form an interlockingrelationship between laterally adjacent shingles 100 a, 100 b. The waterdiverter tab 116 is preferably received by a water diverter tab opening117 in the second side wall 111 of a laterally adjacent shingle. The lip120 of the water diverter tab 116 is preferably captured within a waterdiverter tab recess 119 in the laterally adjacent shingle. The recess119 is preferably bounded by the second side wall 111 and a tab stop121. The tab stop 121 is connected to the bottom surface 103 andpreferably extends the length of the water diverter tab opening 117. Theanchor tab 114 is preferably received by an anchor tab opening 122 inthe first side wall 109 of a laterally adjacent shingle 100.

Turning to FIGS. 5-7, shown therein is the interlocking relationshipcreated by the engagement of the water diverter tabs 116 and anchor tabs114 of laterally adjacent shingles 100. During installation, a fixedshingle 100 b is secured to the underlying surface 200 by placingfasteners 133 in the fastener receiver areas 112 b and through theanchor tab 114 b. The lip 120 a of a free shingle 100 a is then insertedthrough the water diverter tab opening 117 b of the fixed shingle 100 b.The free shingle 100 a is then rotated into a position of contact withthe underlying surface 200. As the free shingle 100 a is rotated, thelip 120 a is captured in the water diverter tab recess 119 between thesecond side wall 111 b and the tab stop 121 b of the fixed shingle 100b. At the same time, the anchor tab 114 b and fastener 133 are receivedin the anchor tab opening 122 in the first side wall 109 a of the freeshingle 100 a. The free shingle 100 a can then be locked into positionby placing fasteners 135 through fastener receiver areas 112 a andanchor tab 114 a. Thus, the fastened anchor tab 114 b works to secureboth of the lower ends 104 a, 104 b of the adjacent shingles 100 a, 100b.

In this way, laterally adjacent shingles 100 a and 100 b can be“interlocked” using the water diverter tab 116 and anchor tab 114 suchthat all four corners of the free shingle 100 a are secured to theunderlying surface 200. Additionally, as demonstrated in FIG. 7, theinterlocked water diverter tab 116 a and anchor tab 114 b cooperativelyform a substantially continuous gutter between the adjacent shingles 100a and 100 b. The interlocking relationship between laterally adjacentshingles 100 a and 100 b provides enhanced resistance to bothprecipitation and high winds.

The interlocking configuration also removes the need in the prior artfor horizontally overlapping a significant proportion of adjacentshingles. Adjacent shingles 100 can be installed without significanthorizontal overlap to maximize the amount of exposure area provided byeach shingle as a percentage of the total surface area required by eachshingle. Maximizing the amount of exposure area provided by each shinglereduces the number of shingles needed to cover a given surface area of aroof. Maximizing the percentage of total exposed surface area of ashingle reduces the amount of raw materials required to cover a givensurface area of a roof. When combined, the larger exposure and thelarger percentage of exposure per shingle provides a more efficient useof raw materials to achieve the water-shedding purpose of roofingshingles.

Referring back to FIG. 3, the shingle 100 also preferably includes aplurality of braces 124. The braces 124 preferably extend downward fromthe bottom surface 103 and extend a portion of the length of the shingle100. The braces 124 enhance the resistance of the shingle 100 to impactfrom debris or hail as well as from compression under a sustainedweight, such as the weight of a contractor standing on the shingle 100.Although three braces 124 are shown in FIG. 3, it will be understood thefewer or greater numbers of braces 124 could also be used, and that theconfiguration of these braces need not all be perpendicular to the lowerend 104 of the shingle 100.

Each shingle 100 also preferably includes a small drain 121 in the lowerend wall 113 in proximity to the water diverter recess 119. The drain121 prevents water captured by the water diverter tab 116 and anchor tab114 from pooling under the shingle 100. The shingle 100 can also includea cross-bar 126 that extends horizontally across the shingle 100. Thecross-bar 126 provides rigidity to the shingle 100 and protects the rooffrom water penetration in the event the lower end 104 is raised by anupdraft or vacuum. In the event an updraft or vacuum raises the lowerend 104, the bottom of the cross-bar 126 remains in close proximity tothe underlying structure.

In a particularly preferred embodiment, the shingle 100 has astepped-profile. FIG. 10 provides an elevational view of the first sidewall 109 of the shingle 100 with the water diverter tab 116 removed forclarity. The first side wall 109 preferably includes a wedge-shapedupper portion 128, a substantially vertical step 130 and a thinner lowerportion 132. The stepped profile of the side wall 109 is configured suchthat the wedge-shaped upper portion 128 supports the shingle 100 on anunderlying surface. As shown in FIGS. 8 and 9, the step 130 isconfigured to rest on the upper end 106 of an adjacent lower shingle100. In this way, the shingle 100 can be easily installed with referenceto a lower shingle with little margin of error by simply resting shingle100 on top of the lower shingle. The automatic alignment provided by thestepped side wall 109 greatly facilitates the installation ofoverlapping field shingles in subsequent courses. In a particularlypreferred embodiment, the side walls 109, 111 and braces 124 are angledwith respect to the top surface 102 to adjust the angle elevation of theshingle 100 off the underlying surface. Specifically, the braces 124 areangled in congruence with the wedge-shaped upper portion of side walls109, 111. The stepped-profile also facilitates the insertion of thewater diverter tab 116 into an adjacent shingle.

In addition to facilitating and improving installation operations, thestepped profile of the shingles 100 also eliminate the presence of thewedge-shaped recesses or “gaps” that result from the overlappedinstallation of conventional rectangular shingles. In the preferredembodiment, the wedge-shaped upper portion 128 is configured tosubstantially occupy the space or “gap” that would be present withstandard planar rectangular shingles. In this way, the wedge-shapedupper portion 128 effectively seals the underside of the shingle 100. Atthe same time, the side walls 109, 111 are configured to accommodate theuse with a traditional “starter” shingle 134, which eliminates the spacebetween the underside of the shingle 100 and the roof surface 200created by the stepped side walls 109, 111 on the first horizontal rowof shingles 100 parallel to the eave of the roof surface 200.

FIG. 11 depicts a presently preferred arrangement of a plurality ofshingles 100. It will be understood that there are a large number ofinstallation methods and configurations for shingles constructed inaccordance with the present invention. In a presently preferredembodiment, however, the shingles 100 are installed by first securingthe bottom portion of a first shingle 100 a to an underlying materialthrough use of an appropriate fastener and the anchor tab 114. The upperleft-hand corner of the first shingle can then be secured by driving asuitable fastener through one or more, preferably two, of the fastenerreceiver areas 112. A second shingle 100 b is then positioned adjacentthe first shingle 100 a by sliding the water diverter tab 116 b underthe second side wall 111 a of the first shingle 100 a. The secondshingle 100 b is then “interlocked” in position adjacent the firstshingle 100 a. The installation of the first shingle 100 a is completedby fastening the upper end 106 a of the first shingle 100 a by driving asuitable fastener through one or more of fastener receiver areas 112.Through this installation process, the water diverter tab 116 b on thesecond shingle 100 b is captured within the water diverter tab recess119 in the first shingle 100 a. This process of interlocking adjacentshingles can be repeated for subsequent shingles 100 in the same course.Subsequent courses of shingles 100 are preferably positioned withreference to the first course by utilizing the vertical step 130.

It is clear that the present invention is well adapted to carry out itsobjectives and attain the ends and advantages mentioned above as well asthose inherent therein. While presently preferred embodiments of theinvention have been described in varying detail for purposes ofdisclosure, it will be understood that numerous changes may be madewhich will readily suggest themselves to those skilled in the art andwhich are encompassed within the spirit of the invention disclosedherein and in the associated claims.

1. A shingle configured for attachment to a roof, the shinglecomprising: a body having a first side wall and a second side wall; awater diverter tab attached to the first side wall; and an anchor tabattached to the second side wall.
 2. The shingle of claim 1, wherein thesecond side wall includes a water diverter tab opening for receiving thewater diverter tab of a laterally adjacent shingle.
 3. The shingle ofclaim 2, wherein the first side wall includes an anchor tab opening forreceiving the anchor tab of a laterally adjacent shingle.
 4. The shingleof claim 3, wherein the shingle further comprises: a water diverter tabstop; and a water diverter tab recess defined by the space between thewater diverter tab stop and the second side wall.
 5. The shingle ofclaim 4, wherein the water diverter tab comprises: a base for channelingwater; and a lip for securing the water diverter tab in the waterdiverter tab recess of a laterally adjacent shingle.
 6. The shingle ofclaim 1, further comprising a plurality of braces extending downwardfrom the body.
 7. The shingle of claim 6, wherein the shingle furthercomprises a cross-bar extending downward from the body and connectingthe plurality of braces.
 8. The shingle of claim 6, wherein theplurality of braces and the first side wall comprise a wedge-shapedportion.
 9. The shingle of claim 1, wherein the shingle comprises adrain adjacent the second side wall for preventing moisture from poolingunder the shingle.
 10. A shingle configured for attachment to a roof,the shingle comprising: a body having a top surface, a bottom surface,an upper end, a lower end, a first side, and a second side, wherein thebody has a width defined as the distance between the first and secondsides, a length defined by the distance between the upper and lowerends; and a water diverter tab attached to the first side for securingthe shingle to a laterally adjacent shingle.
 11. The shingle of claim10, wherein the body further comprises a recess adjacent to the secondside for receiving the water diverter tab of a laterally adjacentshingle.
 12. The shingle of claim 11, wherein the water diverter tabcomprises: a base for channeling water; and a lip for securing the waterdiverter tab in the recess of the laterally adjacent shingle.
 13. Theshingle of claim 12, further comprising: a first side wall extendingdownward from the first side; and a second side wall extending downwardfrom the second side, wherein the recess is adjacent to the second sidewall.
 14. The shingle of claim 13, wherein the second side wall furthercomprises a water diverter tab opening and the first side wall comprisesan anchor tab opening.
 15. The shingle of claim 14, further comprisingan anchor tab attached to the second side for securing the shingle,wherein the anchor tab is configured to receive a fastener.
 16. Theshingle of claim 15, further comprising a brace extending downward fromthe body.
 17. The shingle of claim 16, wherein the brace and the firstside wall comprise a wedge-shaped portion.
 18. A method for installingshingles, the method comprising: securing a first shingle to anunderlying surface by inserting at least one fastener through an upperend of the first shingle and at least one fastener through an anchor tabextending from a first side of the first shingle; interlocking a secondshingle with the first shingle by inserting a water diverter tabconnected to the second side of the second shingle through a waterdiverter tab opening in the first side of the first shingle; andsecuring the second shingle to the underlying surface by inserting atleast one fastener through an upper end of the second shingle and atleast one fastener through an anchor tab extending from a first side ofthe second shingle.
 19. The method of claim 18, wherein the interlockingstep further comprises nesting the anchor tab of the first shingle in ananchor tab opening in the second side of the second shingle.